US20070255515A1 - Methods, systems, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system - Google Patents
Methods, systems, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system Download PDFInfo
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- US20070255515A1 US20070255515A1 US11/799,325 US79932507A US2007255515A1 US 20070255515 A1 US20070255515 A1 US 20070255515A1 US 79932507 A US79932507 A US 79932507A US 2007255515 A1 US2007255515 A1 US 2007255515A1
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- Prior art keywords
- pressure
- hydrant
- loop
- hydrant loop
- leak detection
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
- F17D—PIPE-LINE SYSTEMS; PIPE-LINES
- F17D5/00—Protection or supervision of installations
- F17D5/02—Preventing, monitoring, or locating loss
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M3/00—Investigating fluid-tightness of structures
- G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
- G01M3/26—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
- G01M3/28—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds
- G01M3/2807—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds for pipes
- G01M3/2815—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds for pipes using pressure measurements
Definitions
- the subject matter described herein relates to pressurized fuel piping systems that include hardware peripherals and computer software for automated measurements and recordings. More particularly, the subject matter described herein relates to methods, systems, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system.
- a type III hydrant fuel system is a pressurized fuel distribution system that delivers fuel directly to an aircraft via underground piping.
- a typical type III hydrant fuel system may include several thousand linear feet of fuel distribution piping, a pumphouse with a control room, control panels, control valves, and several fueling pumps for providing the requisite pressure for the distribution of fuel.
- the type III hydrant fuel system may be used by any entity, it is most commonly utilized by military installations, such as U.S. Air Force airbases.
- leak detection systems In light of all of these considerations, most entities utilizing underground pipelines for distributing fuel have implemented some sort of leak detection system. However, the leak detection systems that are utilized are typically operated in a manual manner (either partly or entirely). Thus, the manpower and operation costs associated with these types of leak detection systems may be considerable.
- the subject matter described herein includes methods, systems, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system.
- the method includes automatically actuating one or more valves to isolate a hydrant loop of a type III hydrant fuel piping system from the remainder of the system.
- the pressure in the hydrant loop is varied.
- the pressure in the hydrant loop is measured over time in response to the varying of the pressure.
- the subject matter described herein for automatically detecting a leak in a type III hydrant fuel piping system may be implemented using a computer program product comprising computer executable instructions embodied in a computer readable medium.
- Exemplary computer readable media suitable for implementing the subject matter described herein includes disk memory devices, programmable logic devices, application specific integrated circuits, and downloadable electrical signals.
- a computer readable medium that implements the subject matter described herein may be distributed across multiple physical devices and/or computing platforms.
- FIG. 1 is an exemplary aviation fuel distribution system including a type III hydrant fuel piping system that includes a leak detection system according to an embodiment of the subject matter described herein;
- FIG. 2 is a flow chart illustrating exemplary steps for detecting leaks in a type III hydrant fuel piping system according to an embodiment of the subject matter described herein;
- FIG. 3 depicts an exemplary line graph illustrating the timing of leak detection measurements according to an embodiment of the subject matter described herein;
- FIG. 4 depicts an exemplary pressure curve graph for detecting leaks according to an embodiment of the subject matter described herein;
- FIG. 5A depicts an exemplary computer screen capture of varying pressure measurements according to an embodiment of the subject matter described herein;
- FIG. 5B depicts an exemplary computer screen capture of pressure curves according to an embodiment of the subject matter described herein;
- FIG. 5C depicts an exemplary computer screen capture of a leak detection test result according to an embodiment of the subject matter described herein.
- FIG. 5D depicts an exemplary computer screen capture of the configuration and control of the components identified in FIG. 1 .
- the present subject matter relates to systems, methods, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system.
- the present subject matter performs real time pressure measurements in pressurized underground pipelines to accurately determine the “tightness” of a pipeline system.
- a leak detection system can be incorporated in an existing airport fuel hydrant and transfer piping system, such as a type III hydrant fuel system.
- the LDS may be incorporated into a type III hydrant fuel system at the onset of the fuel system's construction.
- FIG. 1 illustrates an exemplary fuel system 100 in which the present subject matter may be incorporated.
- fuel system 100 may include a type III hydrant fuel system.
- Fuel system 100 includes a plurality of isolation valves 101 - 102 , 105 - 106 , a crossover valve 103 , a motor actuated pressurization/depressurization valve 104 (also known as bypass valve 104 ), a first pressure control valve 123 (with solenoid pilot control valves 121 - 122 ), a second pressure control valve 126 (with solenoid pilot control valves 124 - 125 ), a defuel/flush valve 127 , a pressure transmitter 118 , a hydrant system programmable logic controller (PLC) 109 , fuel storage tanks 113 and 114 , a fuel pump 117 , a filter/separator unit 119 , and piping section 110 .
- the LDS portion of fuel system 100 includes control panel 107 and pressure transmitter 108 .
- Isolation valves 101 - 102 , 105 - 106 include various types of valves that are used to isolate and manipulate at least a portion of piping section 110 . Namely, valves 101 - 102 , 105 - 106 may be opened or closed to isolate or enclose piping section 110 of fuel system 100 for leak detection testing. Likewise, valves 101 - 102 , 105 - 106 may be opened or closed in a particular manner for the normal distribution of fuel to the aircraft fleet depicted in FIG. 1 . In one embodiment, valves 101 - 102 are each equipped with motor actuators so that control panel 107 (via PLC 109 ) is able to control valves 101 - 102 in an automated fashion.
- valves 101 , 102 , 105 , and 106 are double block and bleed valves (DBBVs) and function as isolation valves.
- Valve 103 is a crossover recirculation valve and valve 104 is a motor actuated pressurization/depressurization bypass valve used to increase or decrease the pressure level in piping section 110 during leak detection testing.
- Control valve 123 and control valve 126 may include various types of pressure control valves.
- control valve 123 may include a normal pressure control valve (PCV) (with solenoid control pilot valves (SOVs) 121 - 122 ) and control valve 126 may include a back pressure control valve (BPCV) (with solenoid control pilot valves (SOVs) 124 - 125 ).
- PCV 123 and BPCV 126 are capable of increasing or decreasing the pressure in the piping section 110 (via valve 104 ) depending on which pressure control pilot valve is opened or closed.
- solenoid controlled pilot valves SOVs 121 , 122 , 124 , and 125 may be used to regulate the pressure level in piping section 110 to 75 psi, 50 psi, 120 psi, and 160 psi, respectively.
- control valves 123 and 126 are equipped with solenoids, thereby enabling the pressure control/back pressure control valves to be opened and closed by energizing and de-energizing the solenoids via commands from control panel 107 (via PLC 109 ).
- Valve 127 may include a defuel/flush valve (D/FV) that remains closed during testing. Even though only thirteen valves are shown in FIG. 1 , fuel system 100 may utilize any number of valves without departing from the scope of the present subject matter.
- Control panel 107 sends instructions to hydrant system PLC 109 which is responsible for actuating and confirming that the required fuel system isolation valves are open and/or closed and the designated section(s) of pipeline is isolated and ready to test.
- PLC 109 is also responsible for manipulating the pressure control pilot valves 121 - 126 and bypass valve 104 during a leak detection test based upon instruction from control panel 107 .
- hydrant system PLC 109 Upon completion of a leak detection test, hydrant system PLC 109 checks to ensure that the fuel system valves are returned to their normal operating position for distributing fuel.
- Control panel 107 may include a host interface unit (HIU) 115 and a programmable logic controller (PLC) 116 .
- HIU 115 may include an operator interface that can be used by a system operator to initiate or monitor the pressurized leak detection testing.
- PLC 116 is responsible for interfacing with the existing hydrant system PLC 109 in order to establish the system dual pressure conditions that are used during the leak detection testing to determine the tightness of the system (i.e., obtain a tightness factor).
- PLC 116 may include a computer processor that runs software or firmware programs designed to execute the leak detection tests.
- PLC 116 transmits signals to PLC 109 directing PLC 109 to manipulate (i.e., open and close) valves 101 - 106 , 121 - 126 .
- both PLC 109 and PLC 116 are combined in control panel 107 .
- PLC 116 controls PLC 109 during the leak detection operation
- PLC 109 is the primary controlling unit for all other aspects of operating fuel system 100 .
- EFSO emergency fuel shutoff
- the hydrant system PLC 109 sends a signal to PLC 116 and PLC 116 will abort the leak detection test operation, if applicable.
- Pressure transmitter 108 is responsible for acquiring pressure measurements from piping section 110 (e.g., when isolated) and forwarding the measured data to control panel 107 .
- pressure transmitter 108 is attached to piping section 110 and is coupled to control panel 107 for communication purposes.
- Pressure transmitter 118 is responsible for measuring and relaying pressure readings in the fuel system 100 to the hydrant system PLC 109 .
- Piping section 110 includes a pipeline portion of the system 100 that is used to carry fuel to the fleet of airplanes (see FIG. 1 ). Piping section 110 is often referred to as the hydrant loop of system 100 .
- piping section 110 may include stainless or carbon steel, single wall piping that begins at valve 101 , continues to isolation valve 106 and isolation valve 105 , and terminates at valve 102 .
- piping section 110 may include stainless or carbon steel, double wall piping that begins at valve 101 , continues to isolation valve 106 and isolation valve 105 , and terminates at valve 102 .
- piping section 110 is the pipeline portion of fuel system 100 that is subjected to daily leak detection tests, wherein a single test period lasts for approximately 45 minutes.
- the designated pumphouse hydrant valves along with the installed leak detection hydrant loop bypass pressurization/depressurization valve 104 are controlled by PLC 109 , which receives its commands from control panel 107 .
- a system operator initiates the leak detection test at control panel 107 .
- the leak detection test may be configured to automatically commence at a specific time each day.
- the present subject matter employs the measurement of pressure to determine if a pipeline section of fuel system 100 is leaking.
- One such method for detecting leaks in a type III hydrant fuel system is depicted as method 200 in FIG. 2 .
- one or more valves are automatically actuated to isolate a hydrant loop.
- the control panel 107 (via PLC 109 ) transmits instructions to motor actuators on valves 101 - 106 to isolate piping section 110 (i.e., the “hydrant loop”) from the rest of the system 100 .
- isolation valve 101 and isolation valve 102 are closed to isolate piping section 110 .
- the pressure in the hydrant loop is varied.
- the pressure of piping section 110 is initially lowered to a predefined pressure level (e.g., 50 psi) by control panel 107 .
- control panel 107 sends instructions via PLC 109 to open the pressurization/depressurization bypass valve 104 and pilot valve SOV 122 , the latter of which enables piping section 110 to reach 50 psi.
- the pressure in piping section 110 is raised to a pre-defined high pressure test level by control panel 107 through PLC 109 , which utilizes existing pumps and pressure control valves.
- the necessary high pressure level may be adjusted to a pressure level between 120-160 psi by using BPCV 126 in addition to SOV 124 or SOV 125 .
- SOV 125 receives an instruction from control panel 107 to open, which will allow the system to raise the recirculation piping pressure to 160 psi.
- piping section 110 is then completely isolated and closed tight (via valve 104 ). Notably, piping section 110 is full of fuel and the pressure increase is attributed to the addition of fuel.
- the pressure level in piping section 110 is lowered for a second time.
- the pressure level in piping section 110 is reduced to a low pressure level by first opening pressurization/depressurization valve 104 which caused the pressure to be relieved.
- the low-pressure level may be adjusted (i.e., “fine tuned”) to a pressure level between 40 and 60 psi by using at least one of the PVC pilot valves SOV 121 or SOV 122 .
- SOV 122 is used again to depressurize piping section 110 to 50 psi.
- the pressure in pipe section 110 is subsequently left to settle for a predefined period.
- the pipe section is pressurized to a second high pressure level (e.g., 120 to 160 psi) in an identical manner described to attain the first high pressure level.
- a second high pressure level e.g., 120 to 160 psi
- the pressure in the hydrant loop is measured over time in response to the variation of the pressure levels.
- pressure transmitter 108 obtains “existing” pressure measurements to determine the current pressure level in piping section 110 at several instances over a period of time (i.e., the duration of the leak detection test). Specifically, pressure transmitter 108 takes measurement readings after the predefined settling periods described in block 204 , but before the pressure in piping section 110 is increased or decreased by the control panel 107 (via PLC 109 ). In one embodiment, this alternating sequence of pressurizing pipe section 110 and taking corresponding measurements is known as the pressure-step method.
- pressure transmitter 108 sends the pressure level measurement s in real time to control panel 107 for recording, processing, and evaluation.
- a tightness factor (TF) for the condition of the tested pipe section is calculated.
- a processor at control panel 107 evaluates the collected pressure readings and calculates a TF from the data.
- the pressure data may be applied as input to an algorithm executed by the processor.
- TF tightness factor
- FIG. 3 depicts graph 300 which is defined by a vertical “pressure” axis and a horizontal “time” axis.
- the normal operating pressure of fueling system 100 may be 120 psi.
- the pressure is relieved to a first low pressure level, as indicated by the 50 psi level in FIG. 3 .
- a first set of pressure measurements 301 is recorded.
- the pressure level is increased to a first high pressure (e.g., block 204 of FIG.
- the present subject matter employs the pressure-step method to detect leaks in a tested pipe section.
- the present subject matter may be applied to a type III hydrant fuel system.
- the present subject matter may take advantage of the standardized configuration of a type III hydrant fuel system to automate the leak detection process.
- the leak detection testing is initiated by an operator from a pumphouse control room (not shown in FIG. 1 ) via HIU 115 .
- control panel 107 i.e., PLC 116
- PLC 116 may be programmed to execute the leak detection test automatically at a predefined time selected (e.g., during a non-fueling period).
- Control panel 107 is used to send instructions to hydrant system PLC 109 to actuate and confirm that the appropriate fuel system isolation valves are configured (i.e., closed or opened) to isolate piping section 110 for the leak detection test. Control panel 107 continues to communicate with PLC 109 as necessary to increase or decrease the pressure during the leak detection test. For example, control panel 107 instructs PLC 109 to open the BPCVs. In one embodiment, control panel 107 and PLC 109 may be incorporated into one structure.
- fuel system 100 must be initialized in preparation for the execution of the leak detection test.
- hydrant system PLC 109 is switched to the “OFF” position and a mode selector switch at control panel 107 is set to a “tightness test” mode.
- Control panel 107 may then be used to “energize” pilot control valve 121 to a closed position. Since pilot control valve 121 (among others) is equipped with a solenoid actuator, the valve may be electrically operated by control panel 107 .
- pilot control valve 122 is de-energized to a closed position. Isolation valves 101 - 102 equipped with motorized actuators are subsequently closed, after which crossover valve 103 is instructed to open by control panel 107 .
- D/FV Defuel/flush valve
- control panel 107 is manually prompted by a system operator to commence the test.
- the leak detection process is programmed to automatically begin at a predefined time.
- Control panel 107 (via control panel PLC 116 ) transmits an electronic instruction to automatically open pressurization/depressurization valve 104 (i.e., a motor actuator on valve 104 receives the signal and, in response, mechanically opens the valve).
- control panel 107 sends a signal to de-energize back pressure control pilot valve (BPCV) 124 to the closed position.
- BPCV back pressure control pilot valve
- BPCV pilot valve 125 is energized by control panel 107 to an open position.
- a relay for the lead pump is also enabled by control panel 107 , while D/FV 127 remains closed.
- This configuration enables pressure from BPCV 126 (e.g., 160 psi) to flow into piping section 110 via open valve 104 .
- bypass valve 104 is instructed by control panel 107 to close and the pump relay is subsequently disabled.
- the piping section 110 is then left to settle for a predefined amount of time, after which pressure measurements are sent by pressure transmitter 108 to control panel 107 for recording and processing.
- the pressure is then reduced to a lower pressure level (e.g., 50 psi) by opening bypass valve 104 and opening PCV pilot valve 122 , which establishes the pressure level in piping section 110 to lower to 50 psi.
- Bypass valve 104 is closed once more to isolate piping section 110 .
- Piping section 110 is then left to settle at the lower pressure level for a predefined amount of time, after which another set of pressure measurements is sent by pressure transmitter 108 to control panel 107 .
- Fueling system 100 takes a second set of high pressure readings in the manner described above. Once the pressure readings are sent to control panel 107 , control panel 107 stores and processes the pressure readings using an algorithm to derive a tightness factor (TF).
- the algorithm used to derive the TF is substantially the “pressure-step method” algorithm known to those of skill in the art and includes a number of variables (e.g., pressure reading data, test section volume, pipe wall thickness, product density, etc). This TF is used to indicate the overall integrity of the tested piping section 110 .
- the tightness factor (TF) may be determined by processing pressure measurement results obtained by pressure transmitter 108 .
- the tightness factor may be the leaking liquid volume (e.g., gallons per hour) of the checked pipeline section volume that is typically associated with a standard operating pressure (e.g., 120 psi).
- PLC 116 may generate and store the test results with no further action required on the part of the operator. Similarly, hydrant system PLC 109 is prompted by PLC 116 to return the fuel system valves to their normal operating positions. Also, PLC 116 yields all valve sequencing control back to hydrant system PLC 109 .
- the test results are evaluated and processed by control panel 107 .
- the determination of a leak is largely influenced by temperature and pressure changes during testing.
- the pressure-step method is based on the physical fact that given a defined leak size, the rate of leakage is proportionally larger at a higher pressure than at a lower pressure. Because the leak rate is directly related to a change in pressure, the determination of whether the tested pipe section is satisfactorily “tight” may be ascertained from pressure gradients derived from the leak detection test.
- the test results enable the present subject matter to compare the pressure curves of different pressure levels and determine the tightness factor (TF) irrespective of any temperature change during testing.
- TF tightness factor
- FIG. 4 depicts an exemplary pressure curve graph 400 generated from the obtained pressure level measurements and may be used to indicate a leak in a test piping section.
- the curves in FIG. 4 should be depicted as being horizontal and parallel (e.g., curve 401 and curve 402 ).
- temperature, leaks, and other external effects may result in ascending or descending characteristics. If the system is found to be “not tight,” the leakage rate will be greater at a high test pressure than at a lower test pressure. Consequently, the pressure curves no longer run parallel with respect to each other (e.g., curve 401 and curve 403 ).
- the present subject matter is able to determine the leak rate on the basis of specific properties of the material and geometrical shape of the piping system being tested.
- the evaluated tightness factors are recorded in a statistical database.
- control panel 107 not only utilizes software programs for conducting the leak detection test, but for graphically displaying the pressure measurements for evaluation and the leak detection results.
- Software programs are also utilized for the storage and retrieval of the test data and results.
- FIG. 5A depicts a computer screen capture of the pressure measurements recorded by pressure transmitter 108 .
- This screen capture is an exemplary embodiment of the pressure variations induced in a piping section during the execution of the leak detection test.
- this screen capture is an example similar to the graphical pressure measurement representation depicted in FIG. 3 .
- FIG. 5A depicts a computer screen capture of the pressure measurements recorded by pressure transmitter 108 .
- This screen capture is an exemplary embodiment of the pressure variations induced in a piping section during the execution of the leak detection test.
- this screen capture is an example similar to the graphical pressure measurement representation depicted in FIG. 3 .
- FIG. 5B is an exemplary computer screen capture of the pressure curves generated from the pressure level measurements depicted-in FIG. 5A .
- FIG. 5C is an exemplary computer screen capture of the test results for a tested pipe section(s).
- the test report indicates that a pipe section was tested and exhibited a leak rate percentage that was lower than the leak threshold limit.
- the test result is indicated as “OK” and quantified in a gallons per hour format.
- the test result is given a definitive label as to date/time/test section for data archival and retrieval.
- FIG. 5D is an exemplary computer screen capture of one embodiment of system 100 in FIG. 1 . In this example, the representative components are depicted. In one embodiment, control panel 107 may display the screen depicted in FIG.
- the screen may also be interactive in a manner that enables a system operator to directly manipulate the system components (e.g., using a mouse or touch screen to interact with a given valve). Notably, this screen (and corresponding software) and PLC control allow for the control of the identified components.
Abstract
Description
- The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/796,448, filed May 1, 2006; the disclosure of which is incorporated herein by reference in its entirety.
- The subject matter described herein relates to pressurized fuel piping systems that include hardware peripherals and computer software for automated measurements and recordings. More particularly, the subject matter described herein relates to methods, systems, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system.
- A type III hydrant fuel system is a pressurized fuel distribution system that delivers fuel directly to an aircraft via underground piping. A typical type III hydrant fuel system may include several thousand linear feet of fuel distribution piping, a pumphouse with a control room, control panels, control valves, and several fueling pumps for providing the requisite pressure for the distribution of fuel. Although the type III hydrant fuel system may be used by any entity, it is most commonly utilized by military installations, such as U.S. Air Force airbases.
- Although the use of a type III hydrant fuel system provides an efficient and effective way to fuel a fleet of aircraft, concerns pertaining to its proper operation exist. Namely, there is the concern that the underground pipelines associated with a hydrant fueling system, or any underground fuel system of this type, is susceptible to leaking. Consequently, the U.S. Environmental Protection Agency (EPA) has set forth regulations requiring owners and operators of underground fuel systems to utilize a system capable of detecting deficiencies or compromises in the fuel system that may permit the possibility of product release. More specifically, any facility that transports and provides storage of “water-polluting” products, such as fuel, must be able to detect a release from any portion of a tank and the connected underground fuel piping of these fuel systems. Environmental compliance for these systems is mandated by various state and local authorities.
- In addition to merely abiding to these regulations from a legal perspective, entities utilizing underground fuel piping systems also employ a leak detection means for other reasons. For instance, a military air base may simply wish to operate in accordance to an “environmentally friendly” standard since harmful contaminants and pollutants are being handled. Similarly, if an underground pipe has a leak, excess water or debris can enter the hydrant loop piping system, and thus, may enter the aircraft fuel tank. Consequently, it is imperative that the integrity of the underground pipelines be monitored and maintained.
- In light of all of these considerations, most entities utilizing underground pipelines for distributing fuel have implemented some sort of leak detection system. However, the leak detection systems that are utilized are typically operated in a manual manner (either partly or entirely). Thus, the manpower and operation costs associated with these types of leak detection systems may be considerable.
- Accordingly, there exists a need for methods, systems, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system.
- The subject matter described herein includes methods, systems, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system. In one embodiment, the method includes automatically actuating one or more valves to isolate a hydrant loop of a type III hydrant fuel piping system from the remainder of the system. The pressure in the hydrant loop is varied. The pressure in the hydrant loop is measured over time in response to the varying of the pressure.
- The subject matter described herein for automatically detecting a leak in a type III hydrant fuel piping system may be implemented using a computer program product comprising computer executable instructions embodied in a computer readable medium. Exemplary computer readable media suitable for implementing the subject matter described herein includes disk memory devices, programmable logic devices, application specific integrated circuits, and downloadable electrical signals. In addition, a computer readable medium that implements the subject matter described herein may be distributed across multiple physical devices and/or computing platforms.
- Preferred embodiments of the subject matter described herein will now be explained with reference to the accompanying drawings of which:
-
FIG. 1 is an exemplary aviation fuel distribution system including a type III hydrant fuel piping system that includes a leak detection system according to an embodiment of the subject matter described herein; -
FIG. 2 is a flow chart illustrating exemplary steps for detecting leaks in a type III hydrant fuel piping system according to an embodiment of the subject matter described herein; -
FIG. 3 depicts an exemplary line graph illustrating the timing of leak detection measurements according to an embodiment of the subject matter described herein; -
FIG. 4 depicts an exemplary pressure curve graph for detecting leaks according to an embodiment of the subject matter described herein; -
FIG. 5A depicts an exemplary computer screen capture of varying pressure measurements according to an embodiment of the subject matter described herein; -
FIG. 5B depicts an exemplary computer screen capture of pressure curves according to an embodiment of the subject matter described herein; -
FIG. 5C depicts an exemplary computer screen capture of a leak detection test result according to an embodiment of the subject matter described herein; and -
FIG. 5D depicts an exemplary computer screen capture of the configuration and control of the components identified inFIG. 1 . - The present subject matter relates to systems, methods, and computer program products for automatically detecting leaks in a type III hydrant fuel piping system. Notably, the present subject matter performs real time pressure measurements in pressurized underground pipelines to accurately determine the “tightness” of a pipeline system. In one embodiment, a leak detection system (LDS) can be incorporated in an existing airport fuel hydrant and transfer piping system, such as a type III hydrant fuel system. Alternatively, the LDS may be incorporated into a type III hydrant fuel system at the onset of the fuel system's construction.
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FIG. 1 illustrates anexemplary fuel system 100 in which the present subject matter may be incorporated. In one embodiment,fuel system 100 may include a type III hydrant fuel system.Fuel system 100 includes a plurality of isolation valves 101-102, 105-106, acrossover valve 103, a motor actuated pressurization/depressurization valve 104 (also known as bypass valve 104), a first pressure control valve 123 (with solenoid pilot control valves 121-122), a second pressure control valve 126 (with solenoid pilot control valves 124-125), a defuel/flush valve 127, apressure transmitter 118, a hydrant system programmable logic controller (PLC) 109,fuel storage tanks fuel pump 117, a filter/separator unit 119, andpiping section 110. The LDS portion offuel system 100 includescontrol panel 107 andpressure transmitter 108. In one embodiment, thefuel system 100 may be equipped with a Hydrant Tight® Automated LDS manufactured by Hansa Consult of North America, LLC. - Isolation valves 101-102, 105-106 include various types of valves that are used to isolate and manipulate at least a portion of
piping section 110. Namely, valves 101-102, 105-106 may be opened or closed to isolate or enclosepiping section 110 offuel system 100 for leak detection testing. Likewise, valves 101-102, 105-106 may be opened or closed in a particular manner for the normal distribution of fuel to the aircraft fleet depicted inFIG. 1 . In one embodiment, valves 101-102 are each equipped with motor actuators so that control panel 107 (via PLC 109) is able to control valves 101-102 in an automated fashion. In one embodiment,valves valve 104 is a motor actuated pressurization/depressurization bypass valve used to increase or decrease the pressure level inpiping section 110 during leak detection testing. -
Control valve 123 andcontrol valve 126 may include various types of pressure control valves. For example,control valve 123 may include a normal pressure control valve (PCV) (with solenoid control pilot valves (SOVs) 121-122) andcontrol valve 126 may include a back pressure control valve (BPCV) (with solenoid control pilot valves (SOVs) 124-125). In one embodiment, PCV 123 and BPCV 126 are capable of increasing or decreasing the pressure in the piping section 110 (via valve 104) depending on which pressure control pilot valve is opened or closed. For example, solenoid controlledpilot valves SOVs piping section 110 to 75 psi, 50 psi, 120 psi, and 160 psi, respectively. In one embodiment,control valves Valve 127 may include a defuel/flush valve (D/FV) that remains closed during testing. Even though only thirteen valves are shown inFIG. 1 ,fuel system 100 may utilize any number of valves without departing from the scope of the present subject matter. -
Control panel 107 sends instructions tohydrant system PLC 109 which is responsible for actuating and confirming that the required fuel system isolation valves are open and/or closed and the designated section(s) of pipeline is isolated and ready to test.PLC 109 is also responsible for manipulating the pressure control pilot valves 121-126 andbypass valve 104 during a leak detection test based upon instruction fromcontrol panel 107. Upon completion of a leak detection test,hydrant system PLC 109 checks to ensure that the fuel system valves are returned to their normal operating position for distributing fuel. - Control panel 107 (i.e., an LDS controller) may include a host interface unit (HIU) 115 and a programmable logic controller (PLC) 116.
HIU 115 may include an operator interface that can be used by a system operator to initiate or monitor the pressurized leak detection testing.PLC 116 is responsible for interfacing with the existinghydrant system PLC 109 in order to establish the system dual pressure conditions that are used during the leak detection testing to determine the tightness of the system (i.e., obtain a tightness factor). In one embodiment,PLC 116 may include a computer processor that runs software or firmware programs designed to execute the leak detection tests. Notably,PLC 116 transmits signals toPLC 109 directingPLC 109 to manipulate (i.e., open and close) valves 101-106, 121-126. In one embodiment, bothPLC 109 andPLC 116 are combined incontrol panel 107. AlthoughPLC 116controls PLC 109 during the leak detection operation,PLC 109 is the primary controlling unit for all other aspects of operatingfuel system 100. For example, in an emergency fuel shutoff (EFSO) event, thehydrant system PLC 109 sends a signal toPLC 116 andPLC 116 will abort the leak detection test operation, if applicable. -
Pressure transmitter 108 is responsible for acquiring pressure measurements from piping section 110 (e.g., when isolated) and forwarding the measured data to controlpanel 107. In one embodiment,pressure transmitter 108 is attached topiping section 110 and is coupled to controlpanel 107 for communication purposes.Pressure transmitter 118 is responsible for measuring and relaying pressure readings in thefuel system 100 to thehydrant system PLC 109. -
Piping section 110 includes a pipeline portion of thesystem 100 that is used to carry fuel to the fleet of airplanes (seeFIG. 1 ).Piping section 110 is often referred to as the hydrant loop ofsystem 100. In one embodiment, pipingsection 110 may include stainless or carbon steel, single wall piping that begins atvalve 101, continues toisolation valve 106 and isolation valve 105, and terminates atvalve 102. In another embodiment, pipingsection 110 may include stainless or carbon steel, double wall piping that begins atvalve 101, continues toisolation valve 106 and isolation valve 105, and terminates atvalve 102. In one embodiment, pipingsection 110 is the pipeline portion offuel system 100 that is subjected to daily leak detection tests, wherein a single test period lasts for approximately 45 minutes. - To establish the dual pressures required during testing, the designated pumphouse hydrant valves along with the installed leak detection hydrant loop bypass pressurization/
depressurization valve 104 are controlled byPLC 109, which receives its commands fromcontrol panel 107. - In one embodiment, a system operator initiates the leak detection test at
control panel 107. In one embodiment, the leak detection test may be configured to automatically commence at a specific time each day. - As previously mentioned, the present subject matter employs the measurement of pressure to determine if a pipeline section of
fuel system 100 is leaking. One such method for detecting leaks in a type III hydrant fuel system is depicted asmethod 200 inFIG. 2 . Inblock 202, one or more valves are automatically actuated to isolate a hydrant loop. In one embodiment, the control panel 107 (via PLC 109) transmits instructions to motor actuators on valves 101-106 to isolate piping section 110 (i.e., the “hydrant loop”) from the rest of thesystem 100. Referring toFIG. 1 ,isolation valve 101 andisolation valve 102 are closed to isolatepiping section 110. - In
block 204, the pressure in the hydrant loop is varied. In one embodiment, the pressure ofpiping section 110 is initially lowered to a predefined pressure level (e.g., 50 psi) bycontrol panel 107. Namely,control panel 107 sends instructions viaPLC 109 to open the pressurization/depressurization bypass valve 104 andpilot valve SOV 122, the latter of which enablespiping section 110 to reach 50 psi. After a predefined settling period, the pressure inpiping section 110 is raised to a pre-defined high pressure test level bycontrol panel 107 throughPLC 109, which utilizes existing pumps and pressure control valves. For example, the necessary high pressure level may be adjusted to a pressure level between 120-160 psi by usingBPCV 126 in addition toSOV 124 orSOV 125. In one embodiment,SOV 125 receives an instruction fromcontrol panel 107 to open, which will allow the system to raise the recirculation piping pressure to 160 psi. After capturing the predefined test pressure of 150 psi, pipingsection 110 is then completely isolated and closed tight (via valve 104). Notably, pipingsection 110 is full of fuel and the pressure increase is attributed to the addition of fuel. - After a predefined settling period (e.g., 10 minutes) the pressure level in
piping section 110 is lowered for a second time. For example, the pressure level inpiping section 110 is reduced to a low pressure level by first opening pressurization/depressurization valve 104 which caused the pressure to be relieved. Afterwards, the low-pressure level may be adjusted (i.e., “fine tuned”) to a pressure level between 40 and 60 psi by using at least one of the PVC pilot valves SOV 121 orSOV 122. In one embodiment,SOV 122 is used again to depressurizepiping section 110 to 50 psi. The pressure inpipe section 110 is subsequently left to settle for a predefined period. After the settling time expires, the pipe section is pressurized to a second high pressure level (e.g., 120 to 160 psi) in an identical manner described to attain the first high pressure level. - In
block 206, the pressure in the hydrant loop is measured over time in response to the variation of the pressure levels. In one embodiment,pressure transmitter 108 obtains “existing” pressure measurements to determine the current pressure level inpiping section 110 at several instances over a period of time (i.e., the duration of the leak detection test). Specifically,pressure transmitter 108 takes measurement readings after the predefined settling periods described inblock 204, but before the pressure inpiping section 110 is increased or decreased by the control panel 107 (via PLC 109). In one embodiment, this alternating sequence of pressurizingpipe section 110 and taking corresponding measurements is known as the pressure-step method. - In
block 208, the pressure level measurements are received. In one embodiment,pressure transmitter 108 sends the pressure level measurement s in real time to controlpanel 107 for recording, processing, and evaluation. - In
block 210, a tightness factor (TF) for the condition of the tested pipe section is calculated. In one embodiment, a processor atcontrol panel 107 evaluates the collected pressure readings and calculates a TF from the data. For example, the pressure data may be applied as input to an algorithm executed by the processor. - In
block 212, a determination is made as to whether the calculated tightness factor (TF) is greater than a predefined upper limit threshold. If TF is greater than the upper tolerable limit, thenmethod 200 continues to block 214 where the tested piping section receives a failing result. If TF is less than the upper threshold, thenmethod 200 proceeds to step 216, where the condition of the tested piping section is indicated as “tight” and receives a passing result. Regardless of the test outcome, the TF is recorded and permanently stored bycontrol panel 107 for future reference.Method 200 then ends. -
Method 200 can be further clarified using a graphical illustration afforded byFIG. 3 . Specifically,FIG. 3 depictsgraph 300 which is defined by a vertical “pressure” axis and a horizontal “time” axis. In one embodiment, the normal operating pressure of fuelingsystem 100 may be 120 psi. At the start of the leak detection process (e.g., block 202 ofFIG. 2 ), the pressure is relieved to a first low pressure level, as indicated by the 50 psi level inFIG. 3 . After a settling time of “ST1” (e.g., 3-10 minutes), a first set ofpressure measurements 301 is recorded. Afterwards, the pressure level is increased to a first high pressure (e.g., block 204 ofFIG. 2 ), as indicated by the 150 psi level inFIG. 3 . Similarly, after a settling time of “ST2”, a second set ofpressure measurements 302 is recorded. This process is repeated for the secondlow pressure measurement 303 and secondhigh pressure measurement 304 as shown inFIG. 3 . - As mentioned above, the present subject matter employs the pressure-step method to detect leaks in a tested pipe section. In one embodiment, the present subject matter may be applied to a type III hydrant fuel system. Notably, the present subject matter may take advantage of the standardized configuration of a type III hydrant fuel system to automate the leak detection process. Referring to
FIG. 1 , in one embodiment, the leak detection testing is initiated by an operator from a pumphouse control room (not shown inFIG. 1 ) viaHIU 115. Alternatively, control panel 107 (i.e., PLC 116) may be programmed to execute the leak detection test automatically at a predefined time selected (e.g., during a non-fueling period).Control panel 107 is used to send instructions tohydrant system PLC 109 to actuate and confirm that the appropriate fuel system isolation valves are configured (i.e., closed or opened) to isolatepiping section 110 for the leak detection test.Control panel 107 continues to communicate withPLC 109 as necessary to increase or decrease the pressure during the leak detection test. For example,control panel 107 instructsPLC 109 to open the BPCVs. In one embodiment,control panel 107 andPLC 109 may be incorporated into one structure. - In one embodiment,
fuel system 100 must be initialized in preparation for the execution of the leak detection test. For example,hydrant system PLC 109 is switched to the “OFF” position and a mode selector switch atcontrol panel 107 is set to a “tightness test” mode.Control panel 107 may then be used to “energize”pilot control valve 121 to a closed position. Since pilot control valve 121 (among others) is equipped with a solenoid actuator, the valve may be electrically operated bycontrol panel 107. Similarly,pilot control valve 122 is de-energized to a closed position. Isolation valves 101-102 equipped with motorized actuators are subsequently closed, after whichcrossover valve 103 is instructed to open bycontrol panel 107. By openingcrossover valve 103, the remainder of the pipeline system (i.e., all pipelines except for piping section 110) may be connected as a complete circuit loop. Defuel/flush valve (D/FV) 127 is energized to a closed position bycontrol panel 107. - Once the initialization process is completed, the actual leak detection process may begin. In one embodiment,
control panel 107 is manually prompted by a system operator to commence the test. In an alternate embodiment, the leak detection process is programmed to automatically begin at a predefined time. Control panel 107 (via control panel PLC 116) transmits an electronic instruction to automatically open pressurization/depressurization valve 104 (i.e., a motor actuator onvalve 104 receives the signal and, in response, mechanically opens the valve). Likewise,control panel 107 sends a signal to de-energize back pressure control pilot valve (BPCV) 124 to the closed position. - Next,
BPCV pilot valve 125 is energized bycontrol panel 107 to an open position. A relay for the lead pump is also enabled bycontrol panel 107, while D/FV 127 remains closed. This configuration enables pressure from BPCV 126 (e.g., 160 psi) to flow intopiping section 110 viaopen valve 104. Once the pressure level inpiping section 110 reaches approximately 150 psi,bypass valve 104 is instructed bycontrol panel 107 to close and the pump relay is subsequently disabled. Thepiping section 110 is then left to settle for a predefined amount of time, after which pressure measurements are sent bypressure transmitter 108 to controlpanel 107 for recording and processing. The pressure is then reduced to a lower pressure level (e.g., 50 psi) by openingbypass valve 104 and openingPCV pilot valve 122, which establishes the pressure level inpiping section 110 to lower to 50 psi.Bypass valve 104 is closed once more to isolatepiping section 110.Piping section 110 is then left to settle at the lower pressure level for a predefined amount of time, after which another set of pressure measurements is sent bypressure transmitter 108 to controlpanel 107. - Fueling
system 100 takes a second set of high pressure readings in the manner described above. Once the pressure readings are sent to controlpanel 107,control panel 107 stores and processes the pressure readings using an algorithm to derive a tightness factor (TF). The algorithm used to derive the TF is substantially the “pressure-step method” algorithm known to those of skill in the art and includes a number of variables (e.g., pressure reading data, test section volume, pipe wall thickness, product density, etc). This TF is used to indicate the overall integrity of the testedpiping section 110. Thus, the tightness factor (TF) may be determined by processing pressure measurement results obtained bypressure transmitter 108. In one embodiment, the tightness factor may be the leaking liquid volume (e.g., gallons per hour) of the checked pipeline section volume that is typically associated with a standard operating pressure (e.g., 120 psi). - After the leak detection test is completed,
PLC 116 may generate and store the test results with no further action required on the part of the operator. Similarly,hydrant system PLC 109 is prompted byPLC 116 to return the fuel system valves to their normal operating positions. Also,PLC 116 yields all valve sequencing control back tohydrant system PLC 109. - In one embodiment, the test results are evaluated and processed by
control panel 107. In any pressure based test, the determination of a leak is largely influenced by temperature and pressure changes during testing. The pressure-step method is based on the physical fact that given a defined leak size, the rate of leakage is proportionally larger at a higher pressure than at a lower pressure. Because the leak rate is directly related to a change in pressure, the determination of whether the tested pipe section is satisfactorily “tight” may be ascertained from pressure gradients derived from the leak detection test. The test results enable the present subject matter to compare the pressure curves of different pressure levels and determine the tightness factor (TF) irrespective of any temperature change during testing. -
FIG. 4 depicts an exemplarypressure curve graph 400 generated from the obtained pressure level measurements and may be used to indicate a leak in a test piping section. Assuming ideal conditions, the curves inFIG. 4 should be depicted as being horizontal and parallel (e.g.,curve 401 and curve 402). However, temperature, leaks, and other external effects may result in ascending or descending characteristics. If the system is found to be “not tight,” the leakage rate will be greater at a high test pressure than at a lower test pressure. Consequently, the pressure curves no longer run parallel with respect to each other (e.g.,curve 401 and curve 403). - As mentioned above, despite the significant influence temperature changes may have on pressure levels (and thus, leak determination), the present subject matter does not require temperature measurement or compensation. Any temperature influences are addressed by application of the pressure-step methodology itself.
- Furthermore, the present subject matter is able to determine the leak rate on the basis of specific properties of the material and geometrical shape of the piping system being tested. In one embodiment, the evaluated tightness factors are recorded in a statistical database.
- In one embodiment, the present subject matter is supported by a computer software or firmware program that is executed by a processor in
control panel 107. Namely,control panel 107 not only utilizes software programs for conducting the leak detection test, but for graphically displaying the pressure measurements for evaluation and the leak detection results. Software programs are also utilized for the storage and retrieval of the test data and results. For example,FIG. 5A depicts a computer screen capture of the pressure measurements recorded bypressure transmitter 108. This screen capture is an exemplary embodiment of the pressure variations induced in a piping section during the execution of the leak detection test. Notably, this screen capture is an example similar to the graphical pressure measurement representation depicted inFIG. 3 .FIG. 5B is an exemplary computer screen capture of the pressure curves generated from the pressure level measurements depicted-inFIG. 5A . Similarly,FIG. 5C is an exemplary computer screen capture of the test results for a tested pipe section(s). In this example, the test report indicates that a pipe section was tested and exhibited a leak rate percentage that was lower than the leak threshold limit. The test result is indicated as “OK” and quantified in a gallons per hour format. The test result is given a definitive label as to date/time/test section for data archival and retrieval.FIG. 5D is an exemplary computer screen capture of one embodiment ofsystem 100 inFIG. 1 . In this example, the representative components are depicted. In one embodiment,control panel 107 may display the screen depicted inFIG. 5D . The screen may also be interactive in a manner that enables a system operator to directly manipulate the system components (e.g., using a mouse or touch screen to interact with a given valve). Notably, this screen (and corresponding software) and PLC control allow for the control of the identified components. - It will be understood that various details of the subject matter described herein may be changed without departing from the scope of the subject matter described herein. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation, as the subject matter described herein is defined by the claims as set forth hereinafter.
Claims (22)
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US11/799,325 US7613584B2 (en) | 2006-05-01 | 2007-05-01 | Methods, systems and computer program products for automatically detecting leaks in a hydrant fuel piping system |
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US79644806P | 2006-05-01 | 2006-05-01 | |
US11/799,325 US7613584B2 (en) | 2006-05-01 | 2007-05-01 | Methods, systems and computer program products for automatically detecting leaks in a hydrant fuel piping system |
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US10564653B2 (en) | 2018-04-13 | 2020-02-18 | Mueller International, Llc | Flushing verification and management system |
Also Published As
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WO2007130396A3 (en) | 2008-10-30 |
US7613584B2 (en) | 2009-11-03 |
WO2007130396A2 (en) | 2007-11-15 |
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